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The purpose of this paper is to propose and develop PA2200-based composite powder containing 0-15 Wt.% magnesium oxide before directly using it in selective laser sintering (SLS) machine to produce end-use products for low-volume production in the engineering applications with keen focus to meet the functional requirements which rely on material properties.

The methodology reported emphasises PA2200-based composite powder containing 0-15 Wt.% magnesium oxide development for SLS process which starts with preparation and characterisation of composite material, thermal and rheological study of composite material to decide optimum process parameters for SLS process machine to get optimal part properties. Further, to verify composite material properties, a conventional casting methodology is used. The composition of composite materials those possessing good properties are further selected for processing in SLS process under optimal processing parameters.

The process parameters of SLS machine are material-dependent. The effect of temperature in X-ray diffraction profile is negligible in the case of magnesium oxide reinforced PA2200 composite material. The cyclic heating of material increases melting point temperature, this grounds to modify part bed temperature of material every time before processing on SLS machine to uphold build part properties, as well as material. With the rise in temperature, the Melt flow index and rheological property of materials change. The magnesium oxide reinforced PA2200 composite material has high thermal stability than pure PA2200 material. By the addition of small quantity of magnesium oxide, most of the mechanical property and flammability property improves while elongation at break (percentage) decreases significantly.

The proposed PA2200-based composite powder containing 0-15 Wt.% magnesium oxide material development system and casting metrology to verify developed material properties will be very useful to develop new composite material for SLS process with use of less material. The developed methodology has proven, especially in the case where non-experts or student need to develop composite material for SLS process according to the property requirement of applications.

Unlike earlier composite material development methodology, the projected methodology of polymer-based composite material and confirmation of material properties instead of commencing SLS process provides straight forward means for SLS process composite materials development with less use of the material and period of time.

The purpose of this study is to analyse and optimize the wear parameters of magnesium metal-metal composite. Materials with lesser weight attract both the researcher and industrialists, as it exhibits the performance improvement in the automotive and aerospace industries. The enrichment of mechanical and tribological properties of the existing magnesium focussed the development of new metal–metal composite.

Metal–metal composite with magnesium matrix was synthesized through the disintegrated melt deposition technique with the addition of titanium, aluminium and boron carbide particles. The wear performance of the composite was experimented with the dry sliding wear test by considering load, sliding velocity and sliding distance.

The wear rate of the composite is analysed statistically, and the significance of wear parameters on the wear performance of metal–metal composite is observed. The worn pin surface and the wear debris collected during the wear experiments were exposed to the microscopy analysis to seize the dominating wear mechanisms.

The wear performance of the developed magnesium composite was analysed and discussed in detail with the support of scientific evidence, i.e. worn surface and debris analysis express the wear mechanisms.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2019-0326/

In recent days, friction stir processing (FSP) has emerged as a pioneering approach for the manufacture of composites with enhanced mechanical and tribological properties. The present study aims to examine the impact of process parameters such as tool rotation speed and number of FSP pass on the AZ61A/TiC magnesium metal composite for responses such as hardness and wear resistance.

To minimize number of experimental runs, design of experiment was configured according to the response surface methodology using central composite design. Analysis of variance has been conducted to develop mathematical and empirical model for studying relationship between tool rotation and number of pass for responses such as microhardness and wear resistance. Microhardness was checked on vickers microhardness testing machine, and tribological behavior were examined on pin-on-disc using tribotester. Wear morphology was analyzed via scanning electron microscopy.

The responses were predicted using validated mathematical model, and contour plots were generated to study the interaction and influence of process parameters. Wear observations suggest that for the base magnesium alloy adhesive wear mechanism was dominating and for the developed nanocomposites, abrasive wear mechanism is a prominent factor. It was also observed that both the selected parameters significantly influenced the responses.

To the best of the authors’ knowledge, no prior work has been conducted with this material and preparation of composites with TiC nanoparticles. Furthermore, no mathematical models have been developed to predict the response values.

The high specific strength makes magnesium alloys have a wide range of applications in aerospace, military, automotive, marine and construction industries. However, its poor corrosion resistance and weldability have limited its development and application. Friction stir welding (FSW) can effectively avoid the defects of fusion welding. However, the microstructure, mechanical properties and corrosion behavior of FSW joints in magnesium alloys vary among different regions. The purpose of this paper is to review the corrosion of magnesium alloy FSW joints, and to summarize the protection technology of welded joints.

The corrosion of magnesium alloy FSW joints includes electrochemical corrosion and stress corrosion. This paper summarizes corrosion protection techniques for magnesium alloys FSW joints, focusing on composition, microstructure changes and surface treatment methods.

Currently, this research is mainly focused on enhancing the corrosion resistance of magnesium alloy FSW joints by changing compositions, structural modifications and surface coating technologies. Refinement of the grains can be achieved by adjusting welding process parameters, which in turn minimizes the effects of the second phase on the alloy’s corrosion resistance.

This paper presents a comprehensive review on the corrosion and protection of magnesium alloys FSW joints, covering the latest research advancements and practical applications. It aims to equip researchers with a better insight into the field and inspire new studies on this topic.

The RZ5 mg alloy is used in automotive and aerospace applications including helicopter gearboxes and aircraft components. These components are prone to the wear as per the demands. The present work is the study of the significance of hard particle/ceramic, i.e. titanium carbide (TiC) in RZ5 mg alloy to protect the machine components from wear.

The abrasive wear analysis of in-situ RZ5-TiC magnesium matrix composite is considered for the study. The primary focus of the present work is to analyze the effects of varying control parameters, i.e. Wt.% of TiC, sliding distance and applied load on the responses, i.e. weight loss and coefficient of friction. Full factorial design of the experiment based on statistical analysis is used.

It is observed that the individually Wt.% of TiC and sliding distance show the comparatively significant effect on both responses. Similarly, the interaction between sliding distance and Wt.% of TiC indicated the considerable impact on weight loss. The regression equations are developed and validated for estimating responses. It is observed that the percentage errors are not appearing more than 10 per cent of responses. Therefore, the close agreement between measured and predicted values shows the adequacy of the model. The control factor is optimized using multi-response optimization. The variations of the order of 2.47 and 2.35 per cent in target value of the coefficient of friction and weight loss are achieved.

The current manuscript provides a detailed abrasive wear statistical analysis of RZ5-TiC composite. The influence of control parameters on the responses using the full factorial design, the main effect plots and interaction effects are presented.

This paper aims to determine the optimum parametric settings for yielding superior mechanical properties, namely, ultimate tensile strength (UTS), yield strength (YS) and percentage elongation (EL) of AZ91D/AgNPs/TiO₂ hybrid composite fabricated by friction stir processing.

An empirical model has been developed to govern crucial influencing parameters, namely, rotation speed (RS), tool transverse speed (TS), number of passes (NPS) and reinforcement fraction (RF) or weight percentage. Box Behnken design (BBD) with four input parameters and three levels of each parameter was used to design the experimental work, and analysis of variance (ANOVA) was used to check the acceptability of the developed model. Desirability function analysis (DFA) for a multiresponse optimization approach is integrated with response surface methodology (RSM). The individual desirability index (IDI) was calculated for each response, and a composite desirability index (CDI) was obtained. The optimal parametric settings were determined based on maximum CDI values. A confirmation test is also performed to compare the actual and predicted values of responses.

The relationship between input parameters and output responses (UTS, YS, and EL) was investigated using the Box-Behnken design (BBD). Silver nanoparticles (AgNPs) and nano-sized titanium dioxide (TiO₂) enhanced the ultimate tensile strength and yield strength. It was observed that the inclusion of AgNPs led to an increase in ductility, while the increase in the weight fraction of TiO₂ resulted in a decrease in ductility.

AZ91D/AgNPs/TiO₂ hybrid composite finds enormous applications in biomedical implants, aerospace, sports and aerospace industries, especially where lightweight materials with high strength are critical.

In terms of optimum value through desirability, the experimental trials yield the following results: maximum value of UTS (318.369 MPa), maximum value of YS (200.120 MPa) and EL (7.610) at 1,021 rpm of RS, 70 mm/min of TS, 4 NPS and level 3 of RF.

Friction stir processing (FSP) is overviewed with the process variables, along with the thermal aspect of different metals.

With its inbuilt advantages, FSP is used to reduce the failure in the structural integrity of the body panels of automobiles, airplanes and lashing rails. FSP has excellent process ability and surface treatability with good corrosion resistance and high strength at elevated temperatures. Process parameters such as rotation speed of the tool, traverse speed, tool tilt angle, groove design, volume fraction and increase in number of tool passes should be considered for generating a processed and defect-free surface of the workpiece.

FSP process is used for modifying the surface by reinforcement of composites to improve the mechanical properties and results in the ultrafine grain refinement of microstructure. FSP uses the frictional heat and mechanical deformation for achieving the maximum performance using the low-cost tool; the production time is also very less.

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Altering the microstructure and developing the surface metal matrix composites (MMCs) in a solid-state by friction stir processing (FSP) has been on trend for the past decade. The microstructural modification increases the material properties, which are structure sensitive. The microstructural evolution is highly influenced by the selection of process parameters in FSP. In this study, the effect of process parameters on the microstructure evolution and microhardness of the fabrication of surface MMCs of newly commercialized Mg-ZE41 alloy by the incorporation of different reinforcement particles such as ZrO₂, CeO₂ and Al₂O₃ is investigated.

By making use of Taguchi’s design of experimentation, which recognizes the crucial factors and ascertain their effect on the properties of the material, the optimization of process parameters for this study was done using MATLAB-14 software. The parameters were adopted along with the levels throughout the FSP for the fabrication of different surface MMCs. For each reinforcement particle, two factors at three levels each had L9 factorial design were used to analyse the effect of these factors on the processing result (microstructure, grain refinement and hardness). The two different factors used in this study are tool rotational speed (TRS) and tool traverse speed (TTS) as a part of the full factorial design matrix for different surface MMCs.

Among all combinations, TRS of 1500 rpm and TTS of 20 mm/min. for ZE41-ZrO₂ MMCs and ZE41-CeO₂ MMCs were observed as optimum to produce defect-free processed zone along with the high level of grain refinement and hardness, whereas for ZE41-Al₂O₃ the same was obtained at 1500 rpm TRS and 10 mm/min TTS.

In this paper, the role of process parameters in the development of surface MMCs on newly commercialized Mg-ZE41 alloy by FSP is investigated. The effect of TRS and TTS on microstructure evolution, grain refinement and microhardness is analysed. Hence, in this study, the optimum parameters for the fabrication of surface MMCs of Mg-ZE41 alloy have thus been established.

The purpose of this paper is to provide a perspective of computer‐aided material and process selection (MPS) software tools for product development purpose and present a practical approach for manufacturers and other decision makers involved in MPS.

A multi‐criteria deductive approach for MPS is applied to a case study by taking into account the technical performances and environmental constraints. A resource‐based cost modeling is also deployed to examine the implication of selected material and process on overall product cost.

The paper demonstrates the capabilities and shortcoming of existing computerized MPS software tools in assisting product managers and designers for handling the growing volume of material/process data.

Applying computer‐aided MPS approach to complex shape products with multiple features is not a straightforward task and requires further development in existing MPS software tools.

Computer‐aided MPS systems can assist decision makers in solving many material/process selection problems by following a systematic process.

Given today's rapid technological changes, it is important for decision makers to understand the capabilities of computer‐aided MPS software tools in handling a growing volume of data. Very limited research has been done to explore the capabilities and limitations of existing material/process selectors. It is the first in the literature that demonstrates the application of multi‐criteria deductive approach in MPS using a software tool.

The purpose of this paper is to prepare composite micro-arc oxide coatings with better wear resistance and corrosion resistance.

A nickel powder composite micro-arc oxide film was prepared on the surface of the magnesium alloy by the method of organically combining ultra-fine Ni powder with micro arc oxidation film layer. In this experiment, the changes in the corrosion resistance and microstructure of the composite film layer after adding Ni powder were studied, and the effect of the addition of glycerin on the corrosion resistance of the film layer was analyzed.

The results show that the ultra-fine nickel powder was successfully prepared by the liquid phase reduction method, and the micro-arc oxidation process was modified under the optimal addition amount. The surface of the micro-arc oxide film made of ultra-fine nickel powder was found by SEM to have smooth surfaces and few holes. According to X-ray diffraction analysis, the phase composition of the micro-arc oxide film layer was Mg, Ni, NiSiO₄, MgNi (SiO₄) and Mg₂SiO₄. According to the results of electrochemical tests, the corrosion resistance of the micro-arc oxidation composite film layer was improved after the addition of ultra-fine Ni powder, the corrosion current was greatly reduced and the impedance has been improved. And after adding glycerin, the surface of the film layer becomes denser, and the corrosion resistance of the micro-arc oxide film is significantly improved.

Through this experimental research, a micro-arc oxide coating of powder composite magnesium alloy was successfully prepared. The corrosion resistance of the micro-arc oxidation film layer has been improved, and certain functions had been given to the micro-arc oxidation composite film, which has increased the application field of magnesium alloys.